Contribuição para equipamento didático de máquina de medição por coordenadas

Dissertação de mestrado integrado em Engenharia Mecânica

Desenvolvimento e actualização do controlo de um equipamento de prototipagem rápida

Dissertação de mestrado integrado em Engenharia Mecânica

On the Analysis and Control of a Linear Synchronous Servomotor with a Flexible Load

Industry's growing need for higher productivity is placing new demands on mechanisms connected with electrical motors, because these can easily lead to vibration problems due to fast dynamics. Furthermore, the nonlinear effects caused by a motor frequently reduce servo stability, which diminishes the controller's ability to predict and maintain speed. Hence, the flexibility of a mechanism and its control has become an important area of research. The basic approach in control system engineering is to assume that the mechanism connected to a motor is rigid, so that vibrations in the tool mechanism, reel, gripper or any apparatus connected to the motor are not taken into account. This might reduce the ability of the machine system to carry out its assignment and shorten the lifetime of the equipment. Nonetheless, it is usually more important to know how the mechanism, or in other words the load on the motor, behaves. A nonlinear load control method for a permanent magnet linear synchronous motor is developed and implemented in the thesis. The purpose of the controller is to track a flexible load to the desired velocity reference as fast as possible and without awkward oscillations. The control method is based on an adaptive backstepping algorithm with its stability ensured by the Lyapunov stability theorem. As a reference controller for the backstepping method, a hybrid neural controller is introduced in which the linear motor itself is controlled by a conventional PI velocity controller and the vibration of the associated flexible mechanism is suppressed from an outer control loop using a compensation signal from a multilayer perceptron network. To avoid the local minimum problem entailed in neural networks, the initial weights are searched for offline by means of a differential evolution algorithm. The states of a mechanical system for controllers are estimated using the Kalman filter. The theoretical results obtained from the control design are validated with the lumped mass model for a mechanism. Generalization of the mechanism allows the methods derived here to be widely implemented in machine automation. The control algorithms are first designed in a specially introduced nonlinear simulation model and then implemented in the physical linear motor using a DSP (Digital Signal Processor) application. The measurements prove that both controllers are capable of suppressing vibration, but that the backstepping method is superior to others due to its accuracy of response and stability properties.

Quality assurance of refuse derived fuel with machine vision

This thesis studies the use of machine vision in RDF quality assurance and manufacturing. Currently machine vision is used in recycling and material detection and some commer- cial products are available in the market. In this thesis an on-line machine vision system is proposed for characterizing particle size. The proposed machine vision system is based on the mapping between image segmenta- tion and the ground truth of the particle size. The results shows that the implementation of such machine vision system is feasible.

Efficient Characterisation and Optimal Control of Open Quantum Systems - Mathematical Foundations and Physical Applications

Since no physical system can ever be completely isolated from its environment, the study of open quantum systems is pivotal to reliably and accurately control complex quantum systems. In practice, reliability of the control field needs to be confirmed via certification of the target evolution while accuracy requires the derivation of high-fidelity control schemes in the presence of decoherence. In the first part of this thesis an algebraic framework is presented that allows to determine the minimal requirements on the unique characterisation of arbitrary unitary gates in open quantum systems, independent on the particular physical implementation of the employed quantum device. To this end, a set of theorems is devised that can be used to assess whether a given set of input states on a quantum channel is sufficient to judge whether a desired unitary gate is realised. This allows to determine the minimal input for such a task, which proves to be, quite remarkably, independent of system size. These results allow to elucidate the fundamental limits regarding certification and tomography of open quantum systems. The combination of these insights with state-of-the-art Monte Carlo process certification techniques permits a significant improvement of the scaling when certifying arbitrary unitary gates. This improvement is not only restricted to quantum information devices where the basic information carrier is the qubit but it also extends to systems where the fundamental informational entities can be of arbitary dimensionality, the so-called qudits. The second part of this thesis concerns the impact of these findings from the point of view of Optimal Control Theory (OCT). OCT for quantum systems utilises concepts from engineering such as feedback and optimisation to engineer constructive and destructive interferences in order to steer a physical process in a desired direction. It turns out that the aforementioned mathematical findings allow to deduce novel optimisation functionals that significantly reduce not only the required memory for numerical control algorithms but also the total CPU time required to obtain a certain fidelity for the optimised process. The thesis concludes by discussing two problems of fundamental interest in quantum information processing from the point of view of optimal control - the preparation of pure states and the implementation of unitary gates in open quantum systems. For both cases specific physical examples are considered: for the former the vibrational cooling of molecules via optical pumping and for the latter a superconducting phase qudit implementation. In particular, it is illustrated how features of the environment can be exploited to reach the desired targets.

Stick-slip chaos in a non-ideal self-excited system

In engineering practical systems the excitation source is generally dependent on the system dynamic structure. In this paper we analyze a self-excited oscillating system due to dry friction which interacts with an energy source of limited power supply (non ideal problem). The mechanical system consists of an oscillating system sliding on a moving belt driven by a limited power supply. In the oscillating system considered here, dry friction acts as an excitation mechanism for stick-slip oscillations. The stick-slip chaotic oscillations are investigated because the knowledge of their dynamic characteristics is an important step in system design and control. Many engineering systems present stick-slip chaotic oscillations such as machine tools, oil well drillstrings, car brakes and others.

Comparative study on turning CI and CGI using silicon nitride cutting tools

There has been a great interest for improving the machining of cast iron materials in the automotive and other industries. Comparative studies for tool used to machine grey cast iron (CI) and compacted graphite iron (CGI) on dry machining were also performed in order to find out why in this case the tool lifetime is not significantly higher. However the machining these materials while considering turning with the traditional high-speed steel and carbide cutting tools present any disadvantages. One of these disadvantages is that all the traditional machining processes involve the cooling fluid to remove the heat generated on workpiece due to friction during cutting. This paper present a new generation of ceramic cutting tool exhibiting improved properties and important advances in machining CI and CGI. The tool performance was analyzed in function of flank wear, temperature and roughness, while can be observed that main effects were found for tool wear, were abrasion to CI and inter-diffusion of constituting elements between tool and CGI, causing crater. However the difference in tool lifetime can be explained by the formation of a MnS layer on the tool surface in the case of grey CI. This layer is missing in the case of CGI.

Development of ceramic cutting tools for future application on dry machining

Advanced ceramic materials constitute a mature technology with a very broad base of current and potential applications and a growing list of material compositions. Within the advanced ceramics category, silicon nitride based ceramics are wear-resistant, corrosion-resistant and lightweight materials, and are superior to many materials with regard to stability in high-temperature environments. Because of this combination the silicon nitride ceramics have an especially high potential to resolve a wide number of machining problems in the industries. Presently the Si3N4 ceramic cutting tool inserts are developed using additives powders that are pressed and sintered in the form of a cutting tool insert at a temperature of 1850 °C using pressureless sintering. The microstructure of the material was observed and analyzed using XRD, SEM, and the mechanical response of this array microstructure was characterized for hardness Vickers and fracture toughness. The results show that Si3N4/20 wt.% (AlN and Y 2O3) gives the best balance between hardness Vickers and fracture toughness. The Si3N4/15 wt.% (AlN and Y 2O3) composition allows the production of a very fine-grained microstructure with low decreasing of the fracture toughness and increased hardness Vickers. These ceramic cutting tools present adequate characteristics for future application on dry machining. © (2010) Trans Tech Publications.

Effect of different methods of cutting fluid application on turning of a difficult-to-machine steel (SAE EV-8)

In this study, different methods of cutting fluid application are used in turning of a difficult-to-machine steel (SAE EV-8). Initially, a semisynthetic cutting fluid was applied using a conventional method (i.e. overhead flood cooling), minimum quantity of cutting fluid, and pulverization. A lubricant of vegetable oil (minimum quantity of lubricant) was also applied using the minimum quantity method. Thereafter, a cutting fluid jet under high pressure (3.0 MPa) was singly applied in the following regions: chip-tool interface, top surface of the chip (between workpiece and chip) and tool-workpiece contact. Moreover, two other methods were used: an interflow between conventional application and chip-tool interface jet (combined method) and, finally, three jets simultaneously applied. In order to carry out these tests, it was necessary to set up a high-pressure system using a piston pump for generating a cutting fluid jet, a venturi for fluid application (minimum quantity of cutting fluid and minimum quantity of lubricant) and a nozzle for cutting fluid pulverization. The output variables analyzed included tool life, surface roughness, cutting tool temperature, cutting force, chip form, chip compression rate and machined specimen microstructure. Among the results, it can be observed that the tool life increases and the cutting force decreases with the application of cutting fluid jet, mainly when it is directed to the chip-tool interface. Excluding the methods involving jet fluid, the conventional method seems to be more efficient than other methods of low pressure, such as minimum quantity of volume and pulverization, when considering just the cutting tool wear. © 2013 IMechE.

Different methods of cutting fluid application on turning of a difficult-to-machine steel

Different methods of cutting fluid application are used on turning of a difficult-tomachine steel (SAE EV-8). A semi-synthetic cutting fluid was applied using a conventional method, minimum quantity of cutting fluid (MQCF), and pulverization. By the minimum quantity method was also applied a lubricant of vegetable oil (MQL). Thereafter, a cutting fluid jet under high pressure (3.0 MPa) was singly applied in the following regions: chip-tool interface; top surface of the chip; and tool-workpiece contact. Two other methods were used: an interflow between conventional application and chip-tool interface jet and, finally, three jets simultaneously applied. In order to carry out these tests, it was necessary to set up a high pressure system using a piston pump for generating a cutting fluid jet, a Venturi for fluid application (MQCF and MQL), and a nozzle for cutting fluid pulverization. The output variables analyzed included tool life, surface roughness, cutting tool temperature, cutting force, chip form, chip compression rate and machined specimen microstructure. It can be observed that the tool life increases and the cutting force decreases with the application of cutting fluid jet, mainly when it is directed to the chip-tool interface. Excluding the methods involving jet fluid, the conventional method seems to be more efficient than other methods of low pressure. © (2013) Trans Tech Publications, Switzerland.

Desenvolvimento de uma nova sistemática para centragem e alinhamento da plataforma giratória R-9350 na mandriladora CNC PAMA SPEEDRAM 3000

In heavy machining industries, a critical point that must be taken into account is setup. Because the characteristics of machine tools and parts to be machined, usually pieces robust and large, the preparation of these parts must be made accurately for machining has a good result as planned. As a result of the difficulty raised in the setup machining of heavy parts, companies in this segment seek alternatives to reduce the unproductive time caused by setup and optimize machining processes. One way was found that these companies create operating instructions that describe and standardize the operation between its employees, as well as deploy a control machining times to measure the unproductive time caused by the setup. This work studied a new system for the realization of centering and alignment of Rotating Deck R-9350 in CNC Milling Machine PAMA Speedram 3000, in Liebherr Brazil company. The part Rotating Deck R-9350 is a critical part in which its machining in PAMA Milling Machine is made in three phases and their setup times are quite high and involve stopping the machine. It has been tested and proposed a solution to the realization of this part of the setup without the use of the machine, but of the measuring instrument three-dimensional Laser tracker, with which the machine continued to work, while he was in the centering and alignment of other parts. It was noted that the instrument technically attended the need and it was possible to perform this operation more accurately

A utilização das tecnologias assistidas por computador como elemento de integração, pesquisa e desenvolvimento nas disciplinas de projeto para a engenharia e design

The use of technologies called computedassisted, such as CAD - (Computed Aided Design), CAM - (Computed Aided Manufacturing) and CNC - (Computed Numerical Control), increasingly demanded by the market, are needed in the teaching of subjects technical drawing and design courses for engineering and design. However its use findl barriers in the more conservative wing of the academy, who advocate the use of traditional drawing, for the settling of the concepts and the development of spatial reasoning. This study aimed to show the results obtained with the design and production of an apparatus for measuring a three-dimensional computer-aided milling machine, interaction, integration and consolidation of concepts, fully demonstrating that the learning of computer-assisted technology is possible, and its use is most appropriate, meaningful and productive, than the use of instruments in the classic design.

Difusão de tecnologia CAD e CNC como ferramenta básica de criação e produção em pequena escala, acessível à comunidade

The high competitiveness and the search for newtechnologies that differentiate the product from the project,require the use of new digital tools. The computer aideddesign - Computed Aided Design (CAD), with electronicmodeling, simulation, structural analysis and production,performed in a virtual environment through the applicationof specific software, are available but their use is stilllimited. There are various software available in languagesand extensions to industrial production which, from 3Dmodeling, they can manage through Computer NumericalControl - Computed Numerical Control (CNC) machiningcenters, laminating, stamping, mold making and otherprocesses productive. This project aims to encouragecreativity and entrepreneurship in the community throughthe provision of technology computer aided design - CAD,with a view to implementation of machining technology.

Análise e aferição de uma fresadora CNC através da utilização das tecnologias assistidas por computador, no escaneamento 3D de amostras e processamento de imagens

The use of computer-assisted technologies such as CAD - Computed Aided Design, CAM - Computed Aided Manufacturing, CAE - Computed Aided Engineering and CNC - Computed Numerical Control, are priorities in engineering and product designers. However, the dimensional measurement between the virtual and the real product design requires research, and dissemination procedures among its users. This work aims to use these technologies, through analysis and measurement of a CNC milling machine, designed and assembled in the university. Through the use of 3D scanning, and analyzing images of the machined samples, and its original virtual files, it was possible to compare the sizes of these samples in counterposition to the original virtual dimensions, we can state that the distortions between the real and virtual, are within acceptable limits for this type of equipment. As a secondary objective, this work seeks to disseminate and make more accessible the use of these technologies.

Robotics in ear, nose and throat (ENT) surgery

The three main classes of robotics in ear, nose and throat (ENT) surgery (telemanipulation, image-guided functional servoing, and computer numerical control) are discussed and important examples of applications are described to show both technological and clinical developments. As access to many anatomical features of the head requires very small and compact tools to accurately perform procedures, examples are give in ear surgery where manipulation of the minute ossicles requires fine, dexterous movements.